Crimping tool



R. S. STULL CRIMPING TOOL Sept. 14, 1965 3 Sheets-Sheet 1 Filed NOV. 19, 1962 INVENTOR. Re BERT 5. STULL Sept. 14, 1965 R. s. STULL 3,205,553

CRIMPING TOOL Filed Nov. 19, 1962 3 Sheets-Sheet 2 INVENTOR. ROBERT S. STULL R. S. STULL CRIMPING TOOL Sept. 14, 1965 3 Sheets-Sheet 3 Filed Nov. 19, 1962 INVENTOR. ROBERT S. $TU| BY W WW United States Patent Office 3,205,568 Patented Sept. 14, 1965 3,295,568 CRIMFING T001.

Robert S. Stull, Mechanicsburg, Pa, assignor to AMP Incorporated, Harrisburg, Pa. Filed Nov. 19, 1962, Ser. No. 238,457 3 Claims. ((31. 29-280) This invention relates to improvements in crimping tools of the type utilized to attach electrical connectors to conductors. More particularly, this invention contemplates means cooperating with crimping dies to assure proper alignment of connector components relative to die closure.

One solution to the problem of terminating coaxial cable is taught in U.S. patent application Serial No. 077,114 filed December 20, 1960, now abandoned, in the name of Michael F. OKeefe et al. The connector described therein features a coaxial assembly of circular metal shells or ferrules adapted to be driven in a series of criinps to terminate the outer and inner conductors of a coaxial cable and at the same time provide an extension of the electrical qualities of such cable into connector portions performing a connect-disconnect function. To accomplish the crimp of the center conductor of the coaxial cable at the same time other portions of the connector are crimped, ports are provided in the outer connector ferrule permitting the insertion of dies which engage and compress the inner connector ferrule against the cable center conductor. This feature substantially reduces assembly costs for in addition to reducing the number of steps required the provision of ports in the outer connector ferrule permit the connector to be temporarily positioned in the crimping tool by inserting the inner ferrule die within one of the ports. In the hands of a skilled workman the above procedure offers no problem. In the hands of an unskilled worker or in certain applications wherein the above procedure need be carried out rapidly connector alignment problems arise which may result in the opposing crimping die crushing the connector ferrule or engaging the inner connector ferrule in a manner to form an unsatisfactory crimp.

Accordingly it is one object of the present invention to provide tool improvements operable to assure alignment of a connector assembly relative to crimping die closure thereon.

It is a further object of invention to provide improved tool means operable with crimping die movement to align and hold a connector assembly in a position for proper crimping.

It is still a further object of invention to provide a novel tool means driven by die closure to lift and align the ported ferrule portion of a coaxial connector relative to the line of travel of crimping dies inserted through connector ferrule ports.

It is another object of invention to provide a connector alignment member for a crimping tool permitting rapid and proper crimping operation on coaxial connectors.

It is still another object of invention to provide an attachment for crimping tools adapted to assure alignment of a connector assembly relative to crimping die closure thereon.

Other objects and attainments of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawings in which there is shown and described an illustrative embodiment of the invention; it is to be understood, however, that this embodiment is not intended to be exhaustive nor limiting or" the invention but is given for purposes of illustration in order that others skilled in the art may fully understand the invention and the principles thereof and the manner of applying it in practical use so that they may modify it in various forms, each as may be best suited to the conditions of a particular use.

The foregoing objects are obtained by the present invention through the provision of flange members positioned over and above crimping dies and adapted for movement therewith to engage and guide connector assembly members into a position of alignment relative to die travel. The flange members of the invention are disposed on either side of one crimping die to define surfaces parallel and spaced apart by a distance slightly larger than the outer diameter of a connector over a segment of such connector including the portion to be crimped. The length of the flange members is such as to engage the connector at a point of die travel well before the position wherein the dies begin material compression to perform the crimping operation and thus assure that proper alignment will be effected prior to any opportunity for component damage. It is contemplated that the flange members may be integrally formed with one crimping die or may be part of a separate attachment fitted onto existing dies for the modification of existing tooling.

In the drawings:

FIGURE 1 is a perspective showing one embodiment of the invention incorporated in the head portion of a hand tool of standard construction;

FIGURE 2 is an enlarged sectional View taken along lines 22 of FIGURE 1 showing the embodiment of the invention with the tool in an open position relative to a connector assembly to be crimped, the assembly being loosely held on one crimping die;

FIGURE 3 depicts the structure of FIGURE 2 partially closed showing the alignment feature of the invention in operation;

FIGURE 4 depicts the structure of FIGURE 2 in the fully closed position wtih the die members performing the crimping function;

FIGURE 5 is an enlarged sectional plan view taken along lines 55 of FIGURE 1 showing the tool in an open position with a connector assembly mounted therein;

FIGURE 6 is a perspective showing male and female coaxial connector assemblies of the type described following the crimping operation;

FIGURE 7 is a perspective of a further embodiment of the invention wherein alignment flange members are provided by means of an attachment fitted to an existing crimping tool of standard construction;

FIGURE 8 is an enlarged section taken along the lines 83 of FIGURE 7; and

FIGURE 9 is a perspective showing separately the attachment utilized in FIGURES 7 and 8.

Reference may be had to the aforementioned U.S. patent application S.N. 077,114 for a detailed description of the coaxial connector utilized herein to exemplify the structure and operation of the invention. Briefly summarized with respect to FIGURES 5 and 6, the function of coaxial connector including halves 102 and 112 is to mechanically and electrically interconnect coaxial conductors 111) and 130. nector half 1102 is adapted to fit within female half 11 2 and interlock therewith by spring and frictional engagement to form distinct paths for the inner and outer conductors of cables and 130. Cables 110 and 130.

are first cut and stripped with appropriate lengths of inner and outer conductors exposed and inserted within receiving ferrule portions of each conductor half. The

interior surfaces of the connector ferrule assure that the cable center conductor, braid and a portion of each conductor insulation will be aligned at proper points within each connector half. The design of connector 100 is such that the dimensions of insulation crimping ferrules 104 and 114, braid crimping ferrules 106 and 116 and wire barrel crimping ferrules 109 and 122, respectively,

To accomplish this, male con-.

are the same and may therefore be crimped by' the same dies in a position identical to that of connector half 112 as shown in FIGURE 5. The crimping operation of each connector half is carried out with three distinct crimps being performed simultaneously, upon the respective portions of the connector by three distinct sets of dies commonly mounted and driven.

Turning now to a detailed description of the invention reference may be had to FIGURE 1 wherein one embodiment of the invention is shown mounted for use in a hand tool of standard construction.- The hand tool shown is of the straight action type wherein rotary movement of handles and 12 about handle connecting pin 14 operates to drive handle connecting pins 18 and 22 connected between handle end members 16 and 20, respectively, to drive jaw members 24 and 26 in rotary movement about pin members 32 and 34 held by jaw connecting plates 28 and 30. Jaws 24 and 26 include jaw extensions 36 and 38 each having an interior slot, not 1 shown, defining a surface engaging die driving pin members 40 and 42responsive to jaw movement. Movement of die halves is restrained to a straight line by the cooperation of head portions 50 and 54 of die retaining pins 48 and 52 with slot 47 in die support plate 46 as best shown in FIGURE 5.

The left die halves comprised of three dies 152, 142 and 60 serving as insulation, braid and wire barrel crimping dies, respectively, are secured in an interlocking relationship against relative movement by pin members 40 and 48. Theright die halves 154, 144 and 80 which complement the left die half set are held in a similar fashion by pin members 42 and 52.

In operation movement'forcing handles 10 and 12 together operates to drive pins 18 and 22 outwardly thus driving the lower portions of jaw members 24 and 26 apart and the upper portions 36 and 38 together.

This movement operates to drive each die half inwardly in a movement related to handle movement. The surfaces of die members 60, 142 and 152 and complementary faces 80, 144 and 154 are positioned relative to sections of connector half as shown in FIGURE 5 to engage and perform simultaneous crimps upon the connector. As will be apparent from FIGURE 6, O crimps are utilized for the insulating crimping ferrule 114 and the braid ferrule 116 while a series of partial O crimps is utilized for the wire barrel ferrule 122. The characteristics of such crimp are indicated by the configuration of the indentor dies 60 and80 each having, respectively, raised portions 62 and 66, 86 and 88 and recessed portions 64 and 90. The cross sectional area of each die half 60 and 80 is made in shape and size as slightly less than that of a cross sectional area of the ing tool and/or damage the die faces as a considerable portion of the connector is crushed during the required closure stroke.

Considering now FIGURE 2 more closely it will be noted that connector half 112 hangs in a hinged fashion upon inner die 80 at a point of contact Y with dielectric 124 and a point Z of the ferrule 118 proximate aperture 120. The path of die travel indicated by dotted lines in FIGURES 2 and 3 isprevented from crushing ferrule 118 by the provision of flange members 68 and 76 on each side of indentor die 60 which operate to cam the connector assembly upwardly to align the port 121 with indentor die travel.

Flange members 68 and 7.6 each include rounded portions at the ends thereof adapted to provide a transition surface at the point of contact with both the connector ferrule 18 and flanges 92 and 94 of opposing die half 80.

Thus, flange member 68 includes an outer rounded surface 78 and a inner rounded surface 74 and-flange member '76 includes an outer rounded surface 70 and an inner rounded surface 72. Die half 80 includes spaced flange members 92 and 94 having inner rounded surfaces 96 and 98; the rounded surface operating to assure that a proper enclosure of dies 60 and 80 will be achieved without hanging up of either member of 68 and 76 on members 92 and 94, or of members 68 and 76 on the coaxial connector ferrule 118. It is preferred that the interior surface of members 68 and 76 be polished toa fine polished finish. This feature in connection with the inherent lubrication of the gold plating on ferrule 118 of the coaxial connector operates to assure that the connector shell will slide easily within the surface defined by members 68 and 76.

From the relative dimensions shown it will be apparent that the interior surfaces of members 68 and 76 form parallel surfaces defining a channel of a diameter D which is slightly larger than the diameter of the coaxial connector ferrule 1'18. As a practical matter D may be made equal to approxim-ate the ferrule diameter of the coaxial connector to be crimped plus the maximum variation in manufacturing tolerance expected including gold plating plus one or two mils. For example, if the diameter of a coaxial connector ferrule to be crimped is .250 then the dimension D might be .251 plus .002 or minus .000 inches. The exterior dimension D of members 68 and 76 maybe made slightly less than the, interior dimension D of members 92 and 94 with suflicient thickness to offer substantial rigidity. The length of members '68 and 76 indicated as L should be kept slightly less crimp ports 108 and 120 of the connector halves 102 and 112.. Because of this, dies 60 and 80 may enter opposing die ports and gripand compress the ferrule forming the pin member of a connector such as ferrule 122 of connectorhalf 112 as shown in FIGURE 4.

The standard operating procedure in performing the connections outlined above calls for the usual first step of stripping the cable to bare appropriate lengths of conductor braid and center conductor followed by insertion of the stripped portions into the connector half to be crimped.v Thereafter the connector half maybe hung in an approximately proper position by insertion of the indentor die within a crimping port. FIGURE 2 shows connector half 112 so positioned on die 80. It will be appreciated that unless half 112 is held so that the opposite port 121 is aligned with the path of travel of'the indentor die 60 and particularly the upper edge of'die portions 62 and 66 the die may catch the upper edge of port 121 as at the point X and upon further closure of the dies crush ferrule 118 and ruin the connector. This conditionis aggravated by the use of the so called fool proo crimping tools which cannot be released once clothan the depth of the recess defined by members 92 and 94 indicated as L The width W of members 68 and 76 as shown in FIGURE 5 with respect to 68 should be long enough to offer a surface of contact with the connector ferrule 118 sufficient to prevent cocking of the connector in a verticle sense; i.e., to'hold the connector assembly in proper alignment.

In operation, the progressive closure of dies as shown in FIGURES 2-4 result in the rounded portion surface 74 of member 68 first engaging a line of contact with the surface of the connector ferrule 118 as indicated by C in FIGURE 2. Thereafter with further closure ferrule 118 and the connector assembly 112 will be cammed upwardly about the mechanical hinge formed at, points Y and Z. Further movement will result in ferrule 118 being contacted at an upper point C by the rounded surface 72 of member 76. As, the dies are driven in further closure the connector ferrule '1|18'will be held centered on a line intersecting the ferrule 122 and conductor-126 as well "as the indentor dies 60 and as indicated in FIGURE '3. The ports 120 and 121 being aligned will permit further closure of the die members with an unimpeded entry of-indentor die 60 into port 121. Final closure of the die members as shown in FIGURE 4 may thereafter be accomplished with the central ferrule 122'being compressed in against the center conductor 1-26 to complete the crimping operation. As heretofore indicated, the other dies 142, 144, 152, 154, will simultaneously operate on ferrules 116 and 114 respectively of the connector half '112 to complete the crimping operation. The operation of the flange members 68 and 76 obviates the need to manually or otherwise attempt to hold the connector assembly being crimped in a position so that the cooperating dies will properly enter crimp ports 120 and 121.

The embodiment above described shows flange members incorporated into the indentor dies. The embodiment shown in FIGURES 7, 8 and 9 is for use with existing tooling as an attachment theerto. Viewing now FIG- URE 7, the hand tool including handles it) and 12, jaws 24 and 26' and etc. operates identically to the tool shown in FIGURE 1 the difference residing in the addition of a member 180 and in the die member 160. The indentor dies 150 and 168 have die surfaces identical to the die surfaces heretofore shown and described but without flange members integrally formed therewith. Thus, each die 16% and 168 includes indentor dies 166 and 174 corresponding to indentor dies 69 and Silt of the embodiment of FIGURES 1-5. To this assembly is added an adapter member 180 which includes flange members 184 and 186 serving to guide and align a connector assembly in the manner heretofore described. Member 18%) thus serves as an attachment for modifying existing tool- FIGURES 8 and 9 show how member 18% is secured through the extension of pin 4 therethrough and the right angle surface 182. interlocked against the face of die half 160 in a nesting relationship. Member 180 includes flange members 184 and 186 which fit above and below indentor die 166 and include the features of rounded and polished surfaces in the manner of flanges 68 and 76 described with respect to FIGURE 2. Similarly flanges 184 and 186 are dimensioned to be slightly larger than the maximum diameter of the section of a connector to be crimped. The thickness of each flange may be made such as to provide sliding contact with the interior surfaces of flanges 1'79 and 172 integral with die half 168. The embodiment shown in FIGURES 7, 8 and 9 may be adapted to be used with any straight line action tool of the stacked die type to assure alignment of crimping dies with respect to connector ports of coaxial connectors.

While the embodiments of the invention as above shown and described are related to manually operated hand tools incorporated into semi-automatic power driven tools having similar motions of closure. Additionally, while the embodiments of the invention have been shown relative to coaxial connectors of the type having centrally disposed wire barrel ferrule members with access ports for indentor dies, it is fully contemplated that the aligning feature of the invention may be utilized with other types of connectors wherein the structure of the connector creates a similar problem.

Changes in construction will occur to those skilled in the art and various apparently different modifications and embodiments may be made without departing from the scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective against the prior art.

I claim:

1. In a hand tool for crimping connectors having an outer shell and a central contact member coaxially d-is posed therein with aligned ports in said shell leading to said contact member, the combination comprising first connector carrying means including a pair of fingers having inner parallel surfaces and outer parallel surfaces spaced apart and rigidly supported on a first base member, a first die member extending from said first base member between said fingers and out along a substantial portion of the length of said fingers, a second connector carrying means including a second pair of fingers having inner parallel surfaces spaced to slidingly engage the outer parallel surfaces of said first fingers and support said first connector carrying means against transverse movement, said second fingers being rigidly supported on a second base member, a second die member extending from said second base member between said second fingers and out along a substantial portion of the length thereof and in axial alignment with said first die member, means to drive said first and second connector carrying means in parallel movement of closure to effect an engagement with a connector outer shell having one of the ports thereof fitted over one of the die members and to cam said shell to align the ports thereof and cause said dies to enter said ports to crimp the connector center contact member within said shell.

2. The hand tool of claim 1 wherein said first connector carrying means is integral with said first die memher.

3. The hand tool of claim 1 wherein said first connector carrying means is separate from said first die means.

References Cited by the Examiner UNITED STATES PATENTS 954,297 4/10 Jackson. 1,858,418 5/32 Rowley. 2,468,823 5/49 Housepian 8l426 2,704,358 3/55 Wells. 2,722,146 ll /55 Byrem. 2,992,576 7/61 Evans et al.

WILLIAM FELDM'AN, Primary Examiner. 

1. IN A HAND TOOL FOR CRIMPING CONNECTORS HAVING AN OUTER SHELL AND A CENTRAL CONTACT MEMBER COAXIALLY DISPOSED THEREIN WITH ALIGNED PORTS IN SAID SHELL LEADING TO SAID CONTACT MEMBER, THE COMBINATION COMPRISING FIRST CONNECTOR CARRYING MEANS INCLUDING A PAIR OF FINGERS HAVING INNER PARALLEL SURFACES AND OUTER PARALLEL SURFACES SPACED APART AND RIGIDLY SUPPORTED ON A FIRST BASE MEMBER, A FIRST DIE MEMBER EXTENDING FROM SAID FIRST BASE MEMBER BETWEEN SAID FINGERS AND OUT ALONG A SUBSTANTIAL PORTION OF THE LENGTH OF SAID FINGERS, A SECOND CONNECTOR CARRYING MEANS INCLUDING A SECOND PAIR OF FINGERS HAVING INNER PARALLEL SURFACE OF SAID FIRST FINGERS AND SUPPORT OUTER PARALLEL SURFACES OF SAID FIRST FINGERS AND SUPPORT SAID FIRS CONNECTOR CARRYING MEANS AGAINST TRANSVERSE MOVEMENT, SAID SECOND FINGERS BEING RIGIDLY SUPPORTED ON A SECOND BASE MEMBER, A SECOND DIE MEMBER EXTENDING FROM SAID SECOND BASE MEMBER BETWEEN SAID SECOND FINGERS AND OUT ALONG A SUBSTANTIAL PORTION OF THE LENGTH THEREOF AND IN AXIAL ALIGNMENT WITH SAID FIRST DIE MEMBER, MEANS TO DRIVE SAID FIRST AND SECOND CONNECTOR CARRYENGAGEMENT WITH A CONNECTOR OUTER SHELL HAVING ONE OF THE PORTS THEREOF FITTED OVER ONE OF THE DIE MEMBERS AND TO CAM SAID SHELL TO ALIGN THE PORTS THEREOF AND CAUSE SAID TO CAM SAID SHELL TO ALIGN THE PORTS THEREOF AND CAUSE SAID DIES TO ENTER SAID PORTS TO CRIMP THE CONNECTOR CENTER CONTACT MEMBER WITHIN SAID SHELL. 